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51314-3819-A Five-Year Performance Study of Low VOC Coatings over Zinc Thermal Spray for the Protection of Carbon Steel at the Kennedy Space Center

Picture for A Five-Year Performance Study of Low VOC Coatings over Zinc Thermal Spray for the Protection of Carb
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Product Number: 51314-3819-SG
ISBN: 3819 2014 CP
Author: Mark Kolody
Publication Date: 2014
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$20.00
$20.00
The launch facilities at the Kennedy Space Center are located approximately 1000 feet from the Atlantic Ocean where they are exposed to salt deposits high humidity high UV degradation and acidic exhaust from solid rocket boosters. These assets are constructed from carbon steel which requires a suitable coating to provide long-term protection to reduce corrosion and its associated costs.While currently used coating systems provide excellent corrosion control performance they are subject to occupational safety and environmental regulations at the Federal and State levels that limit their use. Many contain high volatile organic compounds (VOC) hazardous air pollutants and other hazardous materials. Hazardous waste from coating operations include vacuum filters zinc dust hazardous paint related material and solid paint. There are also worker safety issues such as exposure to solvents and isocyanates. To address these issues NASA Corrosion Technology Laboratory personnel investigated top-coated thermal spray zinc coating systems as a promising environmentally friendly protection of carbon steel in an acid launch environment. Additional benefits of the combined coating system include a long service life cathodic protection to the substrate no volatile contaminants and high service temperatures. This paper reports the results of a performance based study to evaluate low VOC topcoats (for thermal spray zinc coatings) on carbon steel for use in a space launch environment. 
The launch facilities at the Kennedy Space Center are located approximately 1000 feet from the Atlantic Ocean where they are exposed to salt deposits high humidity high UV degradation and acidic exhaust from solid rocket boosters. These assets are constructed from carbon steel which requires a suitable coating to provide long-term protection to reduce corrosion and its associated costs.While currently used coating systems provide excellent corrosion control performance they are subject to occupational safety and environmental regulations at the Federal and State levels that limit their use. Many contain high volatile organic compounds (VOC) hazardous air pollutants and other hazardous materials. Hazardous waste from coating operations include vacuum filters zinc dust hazardous paint related material and solid paint. There are also worker safety issues such as exposure to solvents and isocyanates. To address these issues NASA Corrosion Technology Laboratory personnel investigated top-coated thermal spray zinc coating systems as a promising environmentally friendly protection of carbon steel in an acid launch environment. Additional benefits of the combined coating system include a long service life cathodic protection to the substrate no volatile contaminants and high service temperatures. This paper reports the results of a performance based study to evaluate low VOC topcoats (for thermal spray zinc coatings) on carbon steel for use in a space launch environment. 
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Since 1982, there has been a move to Thermal Sprayed Aluminum (TSA) coating in the “splash zone” of offshore structures.  Our experience indicates that an experience applicator, good surface preparation and quality of wire combined to achieve required thickness and apply the sealer to seal the entire surface.

 
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